Cushion and method of manufacture



Nov. 8, 1966 J. A. MARSH ETAL 3,

CUSHION AND METHOD OF MANUFACTURE Filed March 19, 1964 2 Sheets-Sheet 1ATTORNEY 5 J. A. MARSH ETAL CUSHION AND METHOD OF MANUFACTURE Nov. 8,1966 2 Sheets-Sheet 2 Filed March 19, 1964 ATTORNEYS United StatesPatent 3,283,346 CUSHION AND METHOD OF MANUFACTURE John A. Marsh andGeorge W. Armfield, High Point, N.C., assignors to Marsh-Armfield, HighPoint, N.C., a corporation of North Carolina Filed Mar. 19, 1964, Ser.No. 353,222 7 Claims. (Cl. 361) This invention relates to cushions andpillows and intermediate similar articles of manufacture for makingupholstered furniture and to methods for manufacturing the same.Although the invention will be described with reference to cushions andsimilar intermediate upholstering articles especially adapted for use asa seat or a back for upholstered furniture, it will be realized thatcushions or pillows embodying this invention are adapted for other uses.

Cushions of the type with which this invention is concerned are known inthe art and consist usually of a somewhat stiff resilient core orbackbone, preferably polyurethane, covered on its opposite sides withbatts of crimped Dacron fibers. These batts usually are backed on bothsides with cheesecloth, commonly called scrim, which is attached to thebatts by spaced lines of stitching. The assembly of the core or backboneand batts is enclosed within a cloth cover to form a cushion, whichnormally is then sold as an entirety to furniture manufactures and isintended to be subsequently covered with upholstery fabric.

Up to the time of the subject development, cushions of the foregoingnature have been assembled by sewing the batts, about their margins, tothe cover. Initially during this sewing operation the cover is insideout and has an opening along one edge. After the batts are sewn to thecover, the latter is turned right side out and the core is insertedthrough the opening between the batts. After the core has been soinserted, the edges of the cover must then be sewn together along theopening.

The foregoing conventional method of assembly not only is time-consumingecause of the sewing operation, but also requires the use of twodifferent types of sewing machines, one to sew the batts to the cover,and another to sew together the edges of the cover along the opening. Inaddition, the Dacron batts must extend beyond the periphery of theblock-like core in order to provide marginal edge portions which can besewn to the cover with lines of stitching that extend along the edge ofthe cushion. These extended marginal edge portions actually arenonessential in the finished cushion and thus require the use of morebatt material than necessary. Moreover, cushions made by the foregoingmethod have seams that are somewhat bulky.

Additionally, the foregoing mode of assembly results in a product thatis subject to variations in cover tightness because of errors occurringin the sewing operation and also in the operation of cutting the batts.In the event that the cover is too tight, the finished cushion lacks thedesirable soft downy feel. In the event that the cover is too loose, thecushion will be unsightly and lack smoothness because of wrinkles and soforth.

Furthermore, the block or slab-like core in the conventional typecushion is not positively attached to the cover or to the batts, and,consequently, can shift position or crawl within the cushion and thusdistort it out of shape. The latter problem does not exist in cushionsembodying this invention because all elements of the cushion are securedto each other, i.e., the cover to the core, the cover to the batts, andthe batts to the core.

Accordingly, an object of this invention is to provide an improvedcushion that results in savings of both material and time inmanufacture.

A further object of the invention is to provide an improved cushion thatis not subject to variations in cover tightness and which eliminates thebulkiness of sewn seams.

Still another object of the invention is to provide an improved cushionwherein there is no possibility of the core or backbone becomingdisplaced within the cushion.

Another object of this invention is to provide an improved method ofassembling a cushion of the type described which accomplishes theforegoing objects.

A still further object of this invention is to provide a cushion-likeintermediate article of manufacture for making upholstered furniturethat is inexpensive to manufacture.

Referring now to the drawings forming a part of this specification andillustrating a preferred embodiment of the invention:

FIGURE 1 is a perspective view showing the method embodying thisinvention for assembling the various elements of the cushion;

FIGURE 2 is a perspective view of one of the batts of fibers covered onboth sides with scrim;

FIGURE 3 is a perspective view, partially broken away, of an assembledcushion embodying this invention;

FIGURE 4 is a sectional view taken substantially along the line 44 ofFIGURE 3;

FIGURE 5 is a sectional view of a modified type of cushion used as anintermediate article of manufacture;

FIGURE 6 is a perspective view of another modified type of cushion; and

FIGURE 7 is a sectional view taken substantially along the line 7-7 ofFIGURE 6.

Referring now to FIGURES 3 and 4 of the drawings there is shown acushion 10 embodying this invention. The cushion 10, which for exemplarypurposes only is illustrated as being generally right parallelepiped inshape and thus adapted for use as a seat or back cushion for a sofa, achair, or the like, has a slab-like core or backbone 12 of greater widthand length than thickness. The core 12 is of a resilient yet somewhatstiff material, preferably a synthetic resinous foam, e.g.,polyurethane, or material having similar characteristics of resilienceand stiffness.

The core 12 is interposed between two batts of fibers 14, 14 which aregenerally coextensive with the core. Each batt 14 comprises looselymatted fibers 16 preferably covered on opposite sides with scrim 18. Thescrim 18 is attached to each batt 14 by spaced lines of stitching 2i),as shown in FIGURE 2. The loosely matted fibers 16 preferably arecrimped synthetic fibers, preferably polyester fiber such as Dacron.

The batts 14 with the core 12 therebetween are disposed within a cover,of cloth fabric or the like, formed in two parts 22, 22, one for eachmajor side of the cushion, as shown in FIGURES 3 and 4. Each cover part22 has marginal edge portions or flaps 24 that, prior to assembly,extend beyond the peripheral edges of the batts 14 and core 12, as seenbest in FIGURE 1. After assembly, the marginal edge portions 24 of thecover parts 22 are folded over each other in overlapping relation andare bonded to each other by a suitable adhesive. The under or innermostflap 24, and also a portion of the outer flap 24 are bonded by theadhesive to the peripheral edges of the core 12. Moreover, portions ofthe flaps 24 are bonded by adhesive to the peripheral edge of the batts14, while marginal edge portions of the latter are also bonded byadhesive to marginal edge portions of the core 12. Hence, all elementsof the cushion are secured to each other. While various types ofadhesive are suitable, it has been found that an emulsion of latex inwater is very satisfactory.

Referring to FIGURE 1, the improved cushion preflerably is made bystacking the various elements on a lpress generally indicated at 28 andhaving a flat bed 30 land a movable top platen 32, in the followingorder: 1 (1) cover part 22, (2) batt 14, (3) core 12, and cover l part22. The assembled elements are compressed vertically, i.e., in adirection transverse to their planes, by descent of the top platen 32,to precisely the extent which lis desired in the finished product.Preferably the top platen 32 is coextensive with the horizontal outlineof the assembled cushion 10, as shown. \Vhile the assembly is thuscompressed, an operator applies adhesive to the peripheral edges of thebatts 14 and core 12, and to the inner sides of the flaps 24 of thecover parts 22., The adhesive may be applied by a brush (not shown) or 1preferably by a spray gun 34, as shown in FIGURE 1. When using thelatter, the marginal edge portions 24 Iof the cover parts 22 can be heldout to receive the adhesive by the current of air from the gun 34. Afterthe adhesive has been applied, the operator folds the marginal edgeportions 24 of the cover parts 22 into overlapping relation and theybecome bonded to each and to the peripheral edges of the batts 14 andcore 12. 5 Some adhesive also will penetrate and soak between the batts14 and the core .12 and thus bond the marginal edges of these elementstogether. Because of the fore- I going construction, it will be seenthat all of the elements of the cushion are secured to each other, i.e.,the cover to the core, the cover to the batts, and the batts to the 1core. Consequently, the possibility of the core becoming 1 displacedwithin the cushion is eliminated. Additionally, the method of assemblyprovides for a precisely controlled degree of cover-tightness. It is tobe understood that although the invention has l been illustrated anddescribed with reference to a cushion generally in the shape of rightparallelepiped, which may 1 be termed rectangular, the invention isequally applicable 1 to cushions of other shapes, e.g., round, oval,etc. Furthermore, it will be seen that by omitting a batt from 1 oneside of the core a cushion can be constructed, in the i same manner asaforedescribed, that can be used for j what is usually called asemi-attached cushion, i.e., one I wherein the cushion, although made asa separate unit,

; stered furniture.

1' outline as the core.

, Referring now to FIGURE 5, the core 36 is interposed between two battsof fiber 38, 38 that are cut to have substantially the same or slightlylarger size peripheral Each batt comprises loosely matted 5 fiberscovered on opposite sides with scrim 40 made of 1 the same material aspreviously described. After assembly, the marginal edge portions 42 ofthe top layer of scrim of the top batt, and the bottom layer of scrim ofthe bottom batt, are stretched and pulled over the periphadhesive orcement.

eral edges of the core and bonded thereto by a suitable Moreover,marginal edge portions of the fibrous portion of the batts 38, as wellas the 1 scrim 40, are also bonded by adhesive to marginal edge portionsof the core 36. Hence, all elements of the cushion are secured to eachother. In this connection, the scrim or cheesecloth is sufiicientlystretchy so that it can be pulled and stretched as aforesaid to providea product wherein the outer surface of the opposite sides 5 of thecushion is relatively tight.

If desired, one of the batts can be omitted to provide a semi-attachedcushion.

A still further modified embodiment of the invention ;is shown inFIGURES 6 and 7, indicated generally as j 44. Here, as best seen inFIGURE 7, a batt 46 covered on opposite sides with scrim 48 is first cutto a peripheral outline considerably larger than that of a backbone orcore 50 of polyurethane. The batt 46 is then placed to overlie the frontface 52 of the core 50 and the overhanging marginal edges of the battare wrapped around all four peripheral edges of the slab-like backbonemember 50 and bonded to the back face 54 of the backbone member 50, nearthe marginal edges thereof, by an adhesive. Additional bonding strengthmay be provided by applying tape 56 to overlie the marginal edge por'tion of the batt 46 and the adjacent exposed surface of the back face54. All of the elements of this article preferably are of the samematerial as the cushion shown in FIGURES 3 and 4.

The intermediate cushion-like articles of manufacture shown in FIGURES 5and 6 can be enclosed in upholstery fabric in a conventional manner, andthen used for upholstery purposes. The semi-attached article whereinone'of therbatts is omitted can be secured in conventional fashion tothe back of an upholstered piece of furniture, and subsequently coveredwith upholstery fabric. The article shown in FIGURE 6 is used where amore rounded appearance is desired.

Although articles of the type shown in FIGURES 5 and 6 are not asfinished in appearance as a cushion which is provided with a-fabriccover, e.g., FIGURE 3, they are less expensive to make and will SllffiCCfor-certain purposes of manufacturers of upholstered furniture. In thisconnection, it will be realized that a simple cushion of the aforesaidtype also can be made in a variety of shapes and sizes. 4

It will be realized that a manufacturer of upholstered furniture couldeliminate individual cushions and inner springs, simply secure, to theback or seat of the furniture piece, a polyurethane base element whichhas a batt 0f Dacron fibers secured thereto by cement as aforedescribed.In this case, the core of polyurethane would have tobe made thick enoughto take the place of omitted coil springs.

The method of manufacturing the articles shown in FIGURES 5 and 6obviously is similar to the method described above for a cushion havinga two-part cover. In the case of the article shown in FIGURE 5, theplatens used to compress thesbackbone member 36 and the batt 33assembled in overlying relation must be sufiiciently smaller incross-sectional area than the batt to enable the marginal edge portions42 of the scrim on the outer sides of the batt to be pulled intooverlapping relation with the peripheral edge portion of the backbonemember. Also, in compressing the assembled backbone member 50 andoverlying batt 46 shown in FIGURES 6 and 7, the platen used to compressthe back face 54 of the backbone member must be of smaller outline thanthe backbone member to permit the marginal edge portions of the batt tooverlie and be cemented to the marginal edge portions of the back faceof the backbone member and to permit adhesive tape to be applied inoverlying relation with the marginal edge portion of the battand theadjacent exposed areas of the backbone member.

Although specific embodiments of the invention have been shown toillustrate the principles of the invention, it should be clear that manymodifications can be effected that do not depart from these principlesand therefore this invention. should be limited only by th spirit andscope of the following claims.

What is claimed is: 1. A cushion comprising: a cover and a filler, saidfiller including a slab-like backbone member of resilient but somewhatstiff material and at least one batt of loosely-matted fibers overlyingat least one side of said member, said cover being formed in two partsdisposed in overlying relation with the opposite sides of said fillerand having marginal edge portions folded in overlapping relation againstthe peripheral edges of said filler; and an adhesive bonding saidmarginal edge portions to each other, bonding the marginal edge portionsof at least one of said cover parts to the peripheral edges of saidfiller, and bonding together portions of the backbone member and thebatt.

2. A cushion comprising: a cover and a filler, said filler including aslab-like backbone member of resilient but somewhat stifi material andbatts of loosely-matted fibers overlying both sides of said member, saidcover being formed in two parts disposed in overlying relation with theopposite sides of said filler and having marginal edge portions foldedin overlapping relation against the peripheral edges of said filler; andan adhesive bonding said marginal edge portions to each other, bondingthe marginal edge portions of at least one of said cover parts to theperipheral edges of said filler, and bonding together portions of thebackbone member and the batt.

3. The structure defined in claim 1 wherein the adhesive bonds themarginal edge portions of the one cover part to the peripheral edges ofthe backbone member.

4. The structure defined in claim 1 wherein the adhesive bonds themarginal edge portions of the one cover part to the peripheral edges ofboth the backbone member and the batt.

5. The structure defined in claim 1 wherein the adhesive bonds themarginal edge portions of the one cover part to the peripheral edges ofboth the backbone member and the batt, and also bonds together marginaledge portions of said backbone member and said batt.

6. The structure defined in claim 2 wherein the adhesive bonds themarginal edge portions of the one cover part to the peripheral edges ofthe backbone member.

7. The structure defined in claim 2 wherein the adhesive bonds themarginal edge portions of each cover part to the peripheral edges of thebackbone member and to the peripheral edges of the corresponding batt.

References Cited by the Examiner UNITED STATES PATENTS 1,546,689 7/1925Verwys 2991.5 2,271,842 2/ 1942 Nachman 5351 2,546,109 3/ 1951 Puchalsky297219 2,895,542 7/1959 Schutte 5339 2,991,583 7/1961 Carolan 2991.53,019,456 2/1962 Kamp 5-355 3,027,573 4/1962 Bell 5355 3,070,402 12/1962Stanton 297452 3,088,133 5/1963 Waxman 5361 3,110,042 11/1963 Slemmons5-345 3,118,153 1/1964 Hood 5--345 3,170,731 2/1965 Caldemeyer et al.297452 FRANK B. SHERRY, Primary Examiner.

C. A. NUNBERG, Assistant Examiner.

1. A CUSHION COMPRISING: A COVER AND A FILLER, SAID FILLER INCLUDING ASLAB-LIKE BACKBONE MEMBER OF RESILIENT BUT SOMEWHAT STIFF MATERIAL ANDAT LEAST ONE BATT OF LOOSELY-MATTED FIBERS OVERLYING AT LEAST ONE SIDEOF SAID MEMBER. SAID COVER BEING FORMED IN TWO PARTS DISPOSED INOVERLYING RELATION WITH THE OPPOSITE SIDES OF SAID FILLER AND HAVINGMARGINAL EDGE PORTIONS FOLDED IN OVERLAPPING RELATION AGAINST THEPERIPHERAL EDGES OF SAID FILLER; AND AN ADHESIVE BONDING SAID MARGINALEDGE PORTIONS TO EACH